Kenstar KGS15W6P-GDE User manual

Please read this manual carefully to diagnose trouble correctly before offering service.
Record model name & serial number of the machine. Please quote this information when you require service.
STATIONARY STORAGE WATER HEATERS
CLASS-I
KGS15W6P-GDE,KGS15W6M-GDE,
KGS25W6P-GDE, KGS25W6M-GDE
CLASS-II
KGS15W5P , KGS15W5M
KGS25W5P, KGS25W5M
SERVICE MANUAL

INDEX
SR. NO DESCRIPTION PAGE NO
PRODUCT SPECIFICATIONS
MAIN PARTS, THEIR FUNCTIONS & SPECIFICATIONS
TROUBLE SHOOTING
SERVICE SPARE PARTS LIST
EXPLODED VIEW
01
02
03
04
05
SERVICE MANUAL 01
02-03
04
05
06-07
08-10

SERVICE MANUAL
PRODUCT SPECIFICATIONS
SERVICE MANUAL 02
* At Kenstar improvement is continuous process, specification may
change without any notice.

SERVICE MANUAL
PRODUCT SPECIFICATIONS
SERVICE MANUAL 03
* At Kenstar improvement is continuous process, specification may
change without any notice.

MAIN PARTS, THEIR FUNCTIONS & SPECIFICATIONS
SERVICE MANUAL 04
Outer body
SG INSULATION/PUF
INNER TANK
THERMAL CUT OUT POCKET
HEATING ELEMENT
FUSIBLE PLUG
INLET PIPE
VACCUUM RELEASE VALVE
(for Class-II only)
PRESSURE RELEASE VALVE(for Class-II only)
THERMOSTAT POCKET
OUTLET PIPE
INLET PIPE
NEON LAMP
CLASS-I &II
MULTI FUNCTION VALVE( for Class-I only)

TROUBLE SHOOTING
SERVICE MANUAL 05
S. NO.
DEFECTS
POSSIBLE ACTION
ACTION TAKEN
1
GREEN LAMP
NOT GLOWING
MAY BE DUE TO THE DEFFECT OF
LAMP & THERMOSTAT CHECK BOTH.
REPLACE THE DEFECTIVE
PARTS
2
ONLY RED LAMP
GLOWS
THERMOSTAT NOT WORKING
REPLACE THE THERMOSTAT
3
SPARKING INSIDE
THE WATER HEATER
THIS HAPPEN DUE TO THE LOOSE ELECTRIC
CONNECTION AT HEATING ELEMENT
TIGHTEN THE ELECTRIC
CONNECTIONS THEN START THE
WATER HEATER.
4
LEAKAGE
FIRST CHECK THE APPARATUS PLATE AT
HEATING ELEMENT, GASKET & MAIN GASKET
THEN CHECK THE WATER TANK.
IF THERE IS LEAKAGE
CHANGE RESPECTIVE ONE
5
NO HOT WATER
IF GREEN LIGHT GLOWS & NO HOT
WATER IT MEANS ELEMENT PROBLEM.
REPLACE THE HEATING
ELEMENT
6
7

SERVICE MANUAL : METAL BODY 06
EXPLODED VIEW
CLAMPING PAD
CLAMPING
NUT BOLT
CLAMPING
REAR BEADING
BACK COVER
PUF CLAMPING
RING
METAL BODY
SS TANK
ASSLY PLATE
OUTLET PIPE
ELEMENT
FRONT COVER
PUF CLAMPING RING
SHOWCASE
POWER PLUG
THERMOSTAT
THERMAL CUT-OUT
INLET PIPE
LOWER PUF
UPPER PUF
FRONT BEADING
MAIN GASKET
ELEMENT GASKET

07
EXPLODED VIEW
FRONT COVER
UPPER SHOWCASE
HEATING ELEMENT
THERMAL CUT-OUT
THERMOSTAT
CRCA CLAMP
CRCA CLAMP
CLAMP PAD CLAMPING NUT BOLT
GASKET
ASSLY PLATE
UPPER PUF
LOWER PUF
ASSLY PLATE GASKET
SS TANK
REAR COVER
POWER PLUG
LOWER SHOWCASE
INLET PIPE
L-GAURD
TANK
CLAMPING
RING
SERVICE MANUAL : PLASTICS BODY

SERVICE MANUAL 08
Spare Part List
KGT03W1P WATER HEATER,3L INSTANT,KGT03W1P
1100046036 MAIN BODY-3LTR,ABS,KGT03W1P
1100046037 CLAMP,LEG,KGT03W1P
1100046038 TANK,SS 304,1 LTR,KGT03W1P
1100046039 INSTRUCTION MANUAL,KGT03W1P
1300007383 BOX,PACKAGING,5PLY,INNER,PRINTD,KGT03W1P
1300007384 BUFFER THERMOCOL,KGT03W1P
1300007385 BOX,PACKAGING,5 PLY,OUTER,KGT03W1P
K GT 03W1P WATER HEATER,1L INSTANT,K GT01W1P
1100046066 MAIN BODY,ABS,KGT01W1P
1100046067 CLAMP,LEG,KGT01W 1P
1100046068 TAN K,SS 304,1 LT R,KGT01W1P
1100046069 PLAT E,APPARAT US,BRASS,2.1MM,KGT 01W1P
1100046070 PIPE,THERM OSTAT 7",COPPER ,KGT01W 1P
1100046071 PIPE,CUT OUT 7",COPPER,KGT01W1P
1100046072 PIPE,OUTER 4 ",IN+OUT,BRASS,KGT01W1P
1100046073 PIPE,U & I,BRASS,23 ",KGT01W1P
110 0046074 NOZZLE ,BR ASS,KGT01W 1P
110 0046075 PIPE,OUTSIDE,FU SABLE,PVC,KGT0 1W 1P
110 0046076 WASH ER ,FIBER ,R UBBE R,KGT01W 1P
1100046077 REDUCER,BRASS,KGT01W 1P
1100046078 VALVE,SAFETY,BRASS,KGT01W1P
110 0046079 ROD,WELD IN G,COPPE R,K GT 01 W1P
1100046080 THERMOSTAT, 11" / 7",KGT01W1P
1100046081 THERMAL CU T OU T 7",KGT01W1P
110 0046082 CABL E,PVC ,EXTER NAL,48/20,KGT01W 1P
1100046083 WIRE,PVC,INTERNAL,48/20,KGT01W1P
1100046084 NEON LAMP,RED,KGT01W1P
1100046085 NEON LAMP,GREEN,KGT01W 1P
1100046086 ELEM ENT,HEATING,3 KW,KGT01W1P
1100046087 SLEEVE,FIBRE GLASS,KGT01W1P
1100046088 THIMBLES,SMALL,KGT01W 1P
1100046089 THIMBLES,BIG,6MM,KGT01W1P
1100046090 BOLT,6 x 25,M S,KGT01W1P
110 00 46091 WASH ER ,M 6,KGT01W1P
110 00 46092 WASH ER ,S PRING,M 6,K GT 01W1P
1100046093 NUT,6 M M,MS,KGT01W 1P
1100046094 SC REW,6 X 16,SS,KGT01W1P
1100046095 BOLT,H EX,M6 X8,SS,KGT01W1P
1100046096 STUD,SS,M6 x 18,KGT01W1P
110 00 46097 WASH ER ,S S,M 6,KGT01W1 P
110 00 46098 NUT,HE X,M 6,SS,K GT0 1W1 P
110 0046099 WA SH ER ,SPRING,,S S,KGT01 W1P
1100046100 GASKET,127 M M,EPDM,R UBBER,KGT01W 1P
110 0046101 PIP E,PVC ,1/2",THREAD ,KGT0 1W 1P
1100046102 CAP,PVC,KGT01W1P
1100046103 CLIP,CORD,KGT01W1P
110 00 46104 GR OM MET,CORD,KGT01W1P
110 0046105 ELEM EN T,EP DM,RU BBE R,KGT01W 1P
110 0046106 GLASS,WOOL,KGT 01W1P
1100046107 STICKER,LOGO,KGT01W1P
110 0046108 STICKER,TRANSFER ANT ,JACUZ I,KGT 01W1P
1100046109 STICKER,ISI,AL FOIL,KGT01W 1P
1100046110 STICKER,SPECIFIC ATION,AL FOIL,KGT01W1P
110 0046111 STICK ER,BU BB LES,KGT01W 1P
1100046112 INSTR UCTION MANUAL,KGT01W1P
130 0007398 CARTON,IN NE R,PRINT D,5P LY,KGT01W 1P
1300007399 BU FFER TH ER MOCOL,KGT01W1P
1300007400 CARTON,OUTER ,5 PLY,KGT01W1P

SERVICE MANUAL 09
Spare Part List
KGS15W4P WATER HEATER,15L,4*,JACUZZI,KGS15W4P
1100046040 MAIN BODY-15LTR,ABS,KGS15W4P
1100046121 CLAMP,LEG,KGS15W4P
1100046122 TANK,SS 304,15 LTR,KGS15W4P
1100046123 PLATE,APPARATUS,BRASS,2.3MM,KGS15W4P
1100046124 PIPE,THERMOSTAT 11",COPPER,KGS15W4P
1100046125 PIPE,CUT OUT 11",COPPER,KGS15W4P
1100046126 PIPE,U & I,BRASS,4 SOOT ",KGS15W4P
1100046127 NOZZLE,BRASS, 2 SOOT, KGS15W4P
1100046128 VALVE,VACUUM RELEASE, KGS15W4P
1100046129 THERMOSTAT,11", KGS15W4P
1100046130 THERMAL CUT OUT ,11 INCH, KGS15W4P
1100046131 MAINS CORD,PVC,3CORE,32/20,KGS15W4P
1100046132 WIRE,PVC, 1 CORE, 32/20,KGS15W4P
1100046133 ELEMENT,HEATING,2 KW,KGS15W4P
1100046134 SCREW 6x13 SS, KGS15W4P
1100046135 SCREW 6x95 SS, KGS15W4P
1100046136 SCREW 4x12 SS, KGS15W4P
1100046137 PUFF,INSULATION, KGS15W4P
1100046138 INSTRUCTION MANUAL,KGS15W4P
1300007386 BOX,PACKAGING,5PLY,PRINTED,KGS15W4P
1300007387 BUFFER THERMOCOL,KGS15W4P
1300007388 BOX,PACKAGING,5PLY,PRINTD,KGS15W4M
1300007389 BUFFER THERMOCOL,KGS15W4M
KGS15W4M WATER HEATERE,15L,4*,HOT SPRING,KGS15W4
1100046139 MAIN BODY-15LTR,C.R.C.A.,KGS15W4M
1100046140 COVER END,CRC,12.5in,KGS15W4M
1100046141 BRACKET,LEG CLAMP,CRC,KGS15W4M
1100046142 PUFF,INSULATION,KGS15W4M
1100046143 INSTRUCTION MANUAL,KGS15W4M
KGS25W4P WATER HEATER,25L,4*,JACUZZI,KGS25W4P
1100046144 MAIN BODY-25 LTR,ABS,KGS25W4P
1100046145 CLAMP,LEG,KGS25W4P
1100046146 TANK,SS 304,25 LTR,KGS25W4P
1100046147 PIPE,U & I,BRASS,4 SOOT ",KGS25W4P
1100046148 NOZZLE,BRASS, 2 SOOT, KGS25W4P
1100046149 PUFF,INSULATION,KGS25W4P
1100046150 INSTRUCTION MANUAL,KGS25W4P
1300007410 BOX,PACKAGING,5PLY,PRINTD,KGS25W4P
1300007411 BUFFER THERMOCOL,KGS25W4P
KGS25W4M WATER HEATERE,25L,4*,HOT SPRING,KGS25W4M
1100046151 MAIN BODY-25LTR,C.R.C.A.,KGS25W4M
1100046152 COVER END,WITH COV SH,12.5",KGS25W4M
1100046153 BRACKET,LEG CLAMP,CRC,KGS25W4M
1100046154 PUFF,INSULATION, KGS25W4M
1100046155 INSTRUCTION MANUAL,KGS25W4M
1300007412 BOX,PACKAGING,5PLY,PRINTD,KGS25W4M
1300007413 BUFFER THERMOCOL,KGS25W4M

SERVICE MANUAL 10
Spare Part List : Only for Class-1 model.
M at eria l C od e D ES C R Plan t
1 1 00 06 58 6 2 TA N K,SS,K GS 15 W 6 M - G DE /K GS 15 W6 P -G D E S00 1
1 1 00 06 58 6 3 TA N K,SS,K GS 25 W 6 M - G DE /K GS 25 W6 P -G D E S00 1
1 1 00 06 58 6 4 AP AR A TU S P L ATE , K GS 25 W6 P -G D E,15 -2 5L -P /M S00 1
1 1 00 06 58 6 5 M FV , KG S2 5W 6 P- G DE , 1 5- 25 L- P/ M S00 1
1 1 00 06 58 6 6 K N O B SE T,EX TER N A ,KG S2 5W 6 P- G DE ,1 5 -25 L -P /M S00 1
1 1 00 06 58 6 7 ISI, KG S2 5W 6 P- G DE , AL L M O DE L S00 1
1 1 00 06 58 6 8 STIC K ER B E E,KG S1 5W 6 P- G DE S00 1
1 1 00 06 58 6 9 STIC K ER B E E,KG S1 5W 6 M -G D E S00 1
1 1 00 06 58 7 0 STIC K ER B E E,KG S2 5W 6 P- G DE S00 1
1 1 00 06 59 1 1 STIC K ER B E E,KG S2 5W 6 M -G D E S00 1
1 1 00 06 59 1 2 P LA TE R ATIN G , K G S25 W 6P -G D E S00 1
1 1 00 06 59 1 3 P LA TE R ATIN G , K G S15 W 6P -G D E S00 1
1 1 00 06 59 1 4 P LA TE R ATIN G , K G S25 W 6M -G D E S00 1
1 1 00 06 59 1 5 P LA TE R ATIN G ,KG S1 5W 6 M -G D E S00 1
1 1 00 06 59 1 6 M A N U AL , K GS1 5 W6 P -G D E S00 1
11 0 00 65 91 7 STIC K ER C L ASS- 1, K G S15 W 6P -G D E S00 1